All language subtitles for S10E13 - Ice Cream Cones; Tent Trailers; Shoe Polish; Pliers (1080p AMZN WEB-DL x265 Garshasp)_track3_[eng]

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Narrator:
Today on "How it's made"...

Ice-cream cones...

...Tent trailers...

...Shoe polish...

...And pliers.

The ice-cream cone is
The original edible container.

Invented over a century ago,
It adds crunch

To the melt-in-your-mouth taste
Of ice cream.

And it's one container that
Doesn't end up in the trash can,

So you could say it adds
A bit of virtue

To the guilty pleasure
Of the double scoop.

The first ice-cream cones
Were rolled waffles.

And today's cones are simply
Modern versions of that.

Waffle-cone batter starts
With a lot of dark brown sugar.

Caramel coloring is added...

Along with some secret
Flavoring ingredients.

Water is piped into the blender.

It's ice cold to keep the batter
From getting too sticky.

A computer controls
The addition of flour

From a tank on the floor above.

Vegetable oil is added

As a giant beater mixes
All the ingredients.

The batter then flows
Out of the blender

And into a refrigerated tank.

An agitating blade
Keeps the blend

At the consistency
Of pancake batter.

Next, nozzles deposit batter
Onto baking plates

That look
Like moving waffle irons.

Top plates flip down,
And the baking plates roll

Through a glass heated oven
For a quick bake.

The top plates lift up,

Revealing the cooked
Waffle patties.

Automated arms help transfer
The patties to rolling tools.

The tools grab the patties
And twist them into cones.

The cones fall down a chute

And ride an open elevator
Up and down to cool and harden.

The waffle cones
Slide down another chute

And move into lanes
On a conveyor.

Automated fingers help
Guide them into paper jackets.

A computer with a camera eye
Counts the cones

And sends a message to a machine

That stacks them
In the right increments.

Here, a technician
Activates a device

That pushes on a ball
Inside a cone

To test the cone's
Breaking point.

Looks like this waffle cone can
Hold up to some heavy licking.

Over
In the sugar-cone department,

The baking-plate system
Is designed differently.

It makes patties that are
Fan-shaped and have a flat edge.

This shape,
Along with a firmer batter,

Means sugar cones are stronger
Than waffle cones,

So they're a more popular choice
For hard ice cream.

Packers stack the cones
In styrofoam trays.

Then the packages travel
Through a curtain

Of high-density,
Polyethylene film.

A heated sealer
Finishes the wrapping job.

An x-ray machine sends
Information about the contents

To a computer
That counts the cones

And alerts inspectors
To any problems.

Next, automated arms
Pick up cartons and open them

So the packs of cones
Can be inserted.

But there's still one more
Cone variety in the works --

Colorful cake cones.

Cake cones are less sugary
Than other varieties

And have a more
Cake-like texture.

Batter is pumped
Into upright molds.

Cake cones are shaped
Differently

From waffle and sugar cones,

Because they have flat
Rather than pointed bottoms.

Metal cores plunge into
The molds to complete the shape.

This action also enhances
The cake cone's flaky texture.

The cones are baked as they pass
By a gauntlet of gas heaters.

Then it's down a chute and off
To the packaging station.

Unlike the other cones,

Cake cones come out flaky
And crispy

Without a cooling-down period.

A mechanical arm
Picks up paper sleeves

And drops them
In front of the cones.

These cones are now on their way
To an ice-cream stand near you,

Where they'll be used to scoop
Up ice cream lickety-split.

When we return,

Building a tent trailer
From the bottom up.

Narrator:
Tent trailers allow you
To travel without reservations.

Who needs a hotel
If you can park the pop-up?

Besides, you don't get fresh air
And campfires at a hotel.

Tent trailers have been around

Since the early part
Of the 20th century.

And you could describe them
As an overnight success.

Today's tent trailers
Are equipped

With modern conveniences

That would make anyone
A happy camper.

Workers begin production

By welding tubular steel
Components together

To establish a solid framework.

Once it's painted, plumbed,
And partially wired,

Wheels are bolted into place.

The water-storage tank
Goes in next.

Then aircraft-grade steel cables
Are strung

From corner posts
To a central bar.

This bar is called
A "Whiffletree."

Cranking up the whiffletree

Will cause the cables
To lift the corner posts,

Raising the trailer's roof.

The trailer is wheeled
To the next station,

Where workers lower
A vinyl-covered wooden floor

Onto the chassis...

And secure it with screws.

Then they connect a cluster
Of wires

To those already installed
On the chassis

To run things like kitchen
Appliances and stereos.

The interior front wall
Is riveted to steel bulkheads

And the trailer chassis.

More wiring is threaded
Through the bulkheads

To the trailer's side lights,

And then the exterior panel
Is installed.

Workers slide the roadside panel
Over the lift posts

And secure it.

The curbside exterior panels
Come in two pieces

To create a space
For the trailer door.

Corner molding completes
This assembly.

Next, workers move inside

And install the framework
For some bench seating.

They install the lower cabinetry
For the kitchenette,

Then join it
To the upper cabinet

With a long, metal hinge
For easy pivoting.

A mini fridge is inserted
In the lower cabinetry,

And this folding kitchenette
Is complete.

This is the pull-out platform
For one of the mattresses.

It slides into channels
In the exterior walls.

But there's a lot more work to
Do before anyone can take a nap.

The trailer's tent is made
Out of water-resistant fabric.

The five sections
Are sewn separately,

Then zipped together
At an inspection station.

Inspectors scrutinize
Every seam for flaws.

Once the tent passes inspection,

It's fit onto the trailer
One section at a time.

Now it's time
For a little roofing.

The trailer's roof is made

By sandwiching together
Many materials.

And that takes a lot
Of industrial adhesive.

The glue is rolled
Onto these plywood slats.

These foam insulation boards
Also get a generous coating.

Workers place the glued foam

Onto the roof's fiberglass
Outer skin.

They position the wooden slats
Along the perimeter

And add bands of metal
For more reinforcement.

The final layer
Is vinyl-coated plywood.

It will be the ceiling
Of the trailer.

A large roller compresses
The glued layers together.

After grooves and notches
Have been cut into the roof,

It's wired up,

And 12-volt interior lights
Are installed in the ceiling.

Trim is added
To the roof's edges

Along with a gasket
To keep it watertight.

The roof's flaps are folded
In a tray-like configuration,

And the corners are capped.

Workers are now ready to raise
The roof and install the tent.

The assembly is inserted

Into grooves
In the trailer ceiling

Using a pneumatic hammer.

This tent trailer is now ready
To pop up anywhere.

It can accommodate
A small family

And is equipped to feed them
Outdoors or inside.

It even comes
With a screen door,

Because you never know when
Adventure will come knocking.

Coming up, a production line
You can really take a shine to.

Narrator:
Mud and scuffing have long been
The bane of shoes and boots.

In mediaeval times, wax was used

To soften and waterproof
Leather footwear.

But it had a dull finish.

It wasn't
Until the early 20th century

With the invention
Of shoe polish

That footwear
Really started to shine.

All it takes is a bit of polish
And a lot of elbow grease.

A vigorous brushing
Can enhance the job

And help transform shoes
From drab to fab.

Shoe polish starts
With mineral spirit solvent

And different combinations
Of carnauba wax.

The waxes go into a melter,

Where they're heated
To 260 degrees.

The mixture cooks
For 15 minutes,

While beaters keep everything
Blended together.

This is dye fluid
In a deep-black shade.

In another tank, the dye fluid
And waxes are added

To the solvent blend.

Agitators mix it
For three minutes.

Tin-container bottoms
Tumble down a chute

And up a magnetic conveyor belt.

A worker flips the tins
Right-side up

Then pushes them
Onto another conveyor.

Once they're lined up,
They're ready to be filled.

Automated arms space the tins as
They arrive at the filling head.

The filling heads inject hot,
Liquid shoe polish

Into the tins.

The polish is precisely doled
Out so there is no spillover.

The polish now needs
To solidify,

So the tins travel
Through a cooling tunnel.

When they emerge,
The polish is a thick paste.

Workers perform
A breaking-strength test

To be sure the final product
Has the right consistency.

The polish-filled tins
Now funnel onto a conveyor

That merges with a lid feeder.

The feeder lowers the lids
Onto the tins.

A compression wheel
Presses the lids in place

With just the right amount
Of force.

And this polish is now ready
To shine.

There's a different packaging
System for liquid shoe polish.

A blow molding machine
Forces hot air into plastic

To form containers.

Then the mechanized rack
Holding the containers rotates

And places the newly formed
Bottles on another conveyor.

It moves them under a flame,
Which melts the rough edges.

Revolving conveyors move
Under filling heads,

Which pump in liquid polish.

Workers insert valves
Into applicators.

Then this machine
Press-fits the applicators

Onto the polish-filled
Containers.

Using hydraulic pressure,

Another machine snaps clear
Domes onto the applicators.

Rollers affix labels
Onto both sides of the bottles.

The bottles then move
Through an inspection station.

A mirror helps workers
Scrutinize the labeling job.

A technician now takes
A preliminary reading

Of the gloss on some leather.

He applies some paste polish

And rubs it in
With a horsehair brush.

He takes another reading,

And the gloss on this leather
Has increased by a factor of 2,

Which means this polish
Passes muster

And is ready to add some
High luster to your footwear.

When we return,
Plier production --

The gripping truth.

Narrator: pliers date back
To around 2,000 b.C.

Ancient drawings show greek gods
With pliers at the forge.

Today,
Forgers still make pliers,

But these days,
They use automated tools

To shape the metal.

Without them,
A lot of electricians, plumbers,

And mechanics
Would be out of a job.

Pliers have three basic parts --
Handles, a rivet, and jaws.

All the parts are made
From steel

That metal workers forge
Into shape.

First,
A powerful electric furnace

Heats the steel red hot
In just a few seconds.

Then a metal worker
Sets one sizzling rod at a time

On a forming die.

A massive die forger
Hammers the rod against the die

With tons of force.

It takes up to four strikes
On separate impressions

For the rod to acquire
The die's shape.

Then the forging is placed
Onto a press

That trims off any excess steel.

Two forged rods are needed
To make one pair of pliers.

This pair will be for gripping,

So the next step is to machine
The teeth into the jaws.

Workers set the plier halves
Into the broaching machine.

Its tiny cutters,
Dozens of them,

Shave away steel
Under a shower of lubricant.

When the cutters pull away,

The jaw of each plier half
Now has a nice set of teeth.

The factory must heat-treat
The steel to harden it,

A process called "Austempering."

The plier halves travel
Through a gas-fired furnace

For about 2 hours
At a blazing 1,500 degrees.

Then the steel is dunked
In salt water

To cool rapidly and evenly.

The teeth on these pliers will
Have to take a lot of abuse,

So they get
A laser-heat treatment

To make them even harder
And more durable.

Now the pliers are ready
For assembly.

For gripping pliers, a worker
Inserts a single piece ribbon

And joins the two halves.

He then sets the joint
Onto a machine

That spins at high speed,

Generating the force
And friction needed

To set the rivet.

Cutting pliers are also
Held together with a rivet,

But the setting process
Is different.

The parts go into a press that
Applies both heat and pressure

To secure the rivet firmly.

Next, workers insert
The cutting pliers

Between two stone
Grinding wheels.

Again, lubricant prevents
The steel from overheating

As the wheels
Wear down the rivet

Until it lies flush
With the plier surface.

The cutting pliers go
Into a gas oven

For another two hours
Of heat treating,

A process called "Martempering."

When they come out,
They cool in an oil solution

Rather than the salt solution
That cools the gripping pliers.

Steel is a finicky material,
So it's critical

To manage the heat-treating
Process meticulously.

Otherwise,
The metal will be substandard.

After heat-treating, the pliers
Go into a bath of rust inhibitor

That helps protect the steel
From corrosion

And lubricates
The riveted joints.

A robotic arm runs one pair
Of pliers at a time

Against a grinding belt,

Polishing all surfaces except
The handles for a sleek finish.

Then a laser engraves the
Company logo and product number.

Automated bars now lower
Hundreds of pliers handle deep

Into a tank containing
Liquid vinyl.

No messy drips here.

Before dipping,
The factory heat the pliers

To help this coating stick
To the steel.

Next, the pliers go
Into an oven.

The heat hardens
The protective coating,

Cushioning the handles
So they're easier on the hands.

Whatever their shape or size,
Pliers are a toolbox essential

For anyone looking
To ply their trade.

If you have any comments
About the show,

Or if you'd like to suggest
Topics for future shows,

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